CROSS-REFERENCE TO RELATED APPLICATIONSThis is a continuation of U.S. patent application Ser. No. 17/176,292, filed on Feb. 16, 2021, which claims the benefit of priority from U.S. Application No. 62/978,529, filed Feb. 19, 2020, the disclosures of which are hereby incorporated by reference herein in their entirety.
FIELDThis relates to the field of swimming pool cleaners and, more particularly, automatic pool cleaners.
BACKGROUNDAutomatic pool cleaners are designed to move along submerged pool surfaces and remove debris similar to a vacuum cleaner. They may be powered by electricity, positive pressure, or suction. Unfortunately, electric and pressure-powered pool cleaners can be very expensive. Further, many pressure-powered pool cleaner require a second pump to be used to create sufficient pressure.
Suction pool cleaners have several advantages over electric and pressure-powered pool cleaners. Suction pool cleaners are usually much more simple to construct, making them less expensive to manufacture and easier to replace worn parts. And, because suction pool cleaners are powered by the same pump used to operate the pool, they do not require additional pool equipment.
BRIEF SUMMARYA problem with suction pool cleaners is that they can get stuck on submerged obstacles such as drains and can also lose suction and cause the pool pump to air lock if they climb above the waterline of the pool.
A first example of the pool cleaner includes a drive mechanism operable to drive the pool cleaner along a submerged surface of a pool in a forward direction. A housing carried by the drive mechanism has a bottom with an inlet port that receives debris removed from the submerged surface. An outlet port is in fluid communication with the inlet port. A plenum is on the bottom for enhancing suction around the inlet port. A vent mechanism defining at least one opening through the housing is forward the outlet port. A water port defining at least one opening on the bottom is in fluid communication with the vent mechanism. When the forward end of the pool cleaner extends above the waterline of the pool, water flows through the vent mechanism and the water port over the plenum so as to prevent loss of suction at the inlet port.
This first example of the pool cleaner may include one or more of any of the following features.
The vent mechanism and water port may be positioned in such a way that the waterline passes through the vent mechanism and water port simultaneously.
The water port may be positioned forward the inlet port and directly under the vent mechanism.
The plenum may include a recessed area around the inlet port and the water port may be positioned forward the recessed area.
The plenum may include a forward retractable member extending laterally across the bottom and forward the inlet port and the water port may be positioned directly vertical above the forward retractable member.
The vent mechanism may be at least partially positioned forward the outlet port while the plenum includes a forward retractable member extending laterally across the bottom and forward the inlet port. The water port is positioned directly vertical above the forward retractable member and directly under the vent mechanism.
A drive mechanism may be operable to drive the pool cleaner along the submerged surface of a pool in the forward direction and a turning direction using a drive train having a pinion gear that operably mates with a wheel gear on a wheel of the drive mechanism. A cam is operable with the pinion gear and includes a radially enlarged and a radially constricted section arranged about a circumference of the cam. A drive shaft contactor is connected to the pinion gear and cam in such a way that the pool cleaner changes between moving in the forward direction and turning direction when the drive shaft contactor contacts the radially enlarged or the radially constricted section of the cam. The drive shaft contactor is spring biased against the cam about a rotational axis passing through the drive shaft contactor.
The pool cleaner may further include a forward retractable member extending laterally across the bottom and forward the inlet port, a rear retractable member extending laterally across the bottom and rearward the inlet port, and a protruding member extending downwardly from a plenum top surface and longitudinally between the forward retractable member and rear retractable member. When the pool cleaner drives over a submerged obstacle, the protruding member contacts the submerged obstacle and tilts the pool cleaner to prevent the pool cleaner from becoming stuck on the submerged obstacle.
A second example of the pool cleaner includes a drive mechanism operable to drive the pool cleaner along a submerged surface of a pool in a forward direction. A housing carried by the drive mechanism has a bottom with an inlet port that receives debris removed from the submerged surface. An outlet port is in fluid communication with the inlet port. A plenum is on the bottom for enhancing suction around the inlet port. A forward retractable member extends laterally across the bottom and forward the inlet port. A rear retractable member extends laterally across the bottom and rearward the inlet port. A protruding member extends downwardly from a plenum top surface and longitudinally between the forward retractable member and rear retractable member. When the pool cleaner drives over a submerged obstacle, the protruding member contacts the submerged obstacle and tilts the pool cleaner to prevent the pool cleaner from becoming stuck on the submerged obstacle.
This second example of the pool cleaner may include one or more of any of the following features.
When a forward end of the pool cleaner extends above a waterline of the pool, water flows through a vent mechanism and a water port of the housing and over the plenum so as to prevent loss of suction at the inlet port. The vent mechanism and water port are positioned on the housing in such a way that the waterline passes through the vent mechanism and water port simultaneously.
The plenum may include a forward vertical wall forward the inlet port and a rear vertical wall rearward the inlet port where the protruding member contacts the forward vertical wall and rear vertical wall.
The plenum may include a recessed area around the inlet port and the protruding member may extend downwardly out of the recessed area.
The pool cleaner may also include a vent mechanism defining at least one opening through a top of the housing and a water port defining at least one opening on the bottom. The water port is in fluid communication with the vent mechanism. When a forward end of the pool cleaner extends above a waterline of the pool, water flows through the vent mechanism and the water port over the plenum so as to prevent loss of suction at the inlet port.
The drive mechanism may be operable to drive the pool cleaner along the submerged surface of a pool in the forward direction and a turning direction using a drive train having a pinion gear that operably mates with a wheel gear on a wheel of the drive mechanism. A cam operable with the pinion gear includes a radially enlarged and a radially constricted section arranged about a circumference of the cam. A drive shaft contactor is connected to the pinion gear and cam in such a way that the pool cleaner changes between moving in the forward direction and turning direction when the drive shaft contactor contacts the radially enlarged or the radially constricted section of the cam. The drive shaft contactor is spring biased against the cam about a rotational axis passing through the drive shaft contactor.
A third example of the pool cleaner includes a drive mechanism operable to drive the pool cleaner along a submerged surface of a pool in a forward direction and a turning direction using a drive train having a pinion gear that operably mates with a wheel gear on a first wheel of the drive mechanism. A housing carried by the drive mechanism has a bottom with an inlet port that receives debris removed from the submerged surface. An outlet port is in fluid communication with the inlet port. A cam operable with the pinion gear includes a radially enlarged and a radially constricted section arranged about a circumference of the cam. A drive shaft contactor is connected to the pinion gear and cam in such a way that the pool cleaner changes between moving in the forward direction and turning direction when the drive shaft contactor contacts the radially enlarged or the radially constricted section of the cam. The drive shaft contactor is spring biased against the cam about a rotational axis passing through the drive shaft contactor.
This third example of the pool cleaner may include one or more of any of the following features.
When a forward end of the pool cleaner extends above a waterline of the pool, water flows through a vent mechanism and a water port of the housing and over a plenum on the bottom for enhancing suction around the inlet port so as to prevent loss of suction at the inlet port, the vent mechanism and water port being positioned on the housing in such a way that the waterline passes through the vent mechanism and water port simultaneously.
The pool cleaner may also include a plenum formed on the bottom for enhancing suction around the inlet port, a vent mechanism defining at least one opening through a top of the housing, and a water port defining at least one opening on the bottom. The water port is in fluid communication with the vent mechanism. When a forward end of the pool cleaner extends above a waterline of the pool, water flows through the vent mechanism and the water port over the plenum so as to prevent loss of suction at the inlet port.
The pool cleaner may also include a plenum formed on the bottom for enhancing suction around the inlet port, a forward retractable member extending laterally across the bottom and forward the inlet port, and a rear retractable member extending laterally across the bottom and rearward the inlet port. A protruding member extends downwardly from a plenum top surface and longitudinally between the forward retractable member and rear retractable member. When the pool cleaner drives over a submerged obstacle, the protruding member contacts the submerged obstacle and tilts the pool cleaner to prevent the pool cleaner from becoming stuck on the submerged obstacle.
The drive mechanism may include a track wrapped around the first wheel and a second wheel, the first wheel having a larger diameter than the second wheel.
The drive mechanism may include a track wrapped around the first wheel and a second wheel. The track, first wheel, and second wheel define a space therebetween. A guard substantially fills the space to prevent objects from entering the space.
BRIEF DESCRIPTION OF THE DRAWINGSFIG.1 is a perspective view from a forward end and top of an example of the pool cleaner.
FIG.2 is a perspective view from a forward end and bottom thereof.
FIG.3 is a top view thereof.
FIG.4 is a bottom view thereof.
FIG.5 is a side view thereof.
FIG.6 is the opposite side view thereof.
FIG.7 is a forward end view thereof.
FIG.8 is a back end view thereof.
FIG.9 is a front end view thereof with the forward retractable member shown as a transparent feature.
FIG.10 is a back end view thereof with the rear retractable member shown as a transparent feature.
FIG.11 is a cross-section view taken along plane11-11 inFIGS.9 and10.
FIG.12 is a similar view as inFIG.1 with the cover removed.
FIG.13 is a side view of an example of the outlet port housing.
FIG.14 is a top view of the pool cleaner with the cover and outlet port housing removed.
FIG.15 is a partially exploded zoom view of a portion of the drive train.
FIG.16 is a side perspective view of the drive train.
FIG.17 is an opposite side perspective view of the drive train.
FIG.18 is a side view of the drive train with the drive shaft contactor in a forward drive position.
FIG.19 is a side view of the drive train with the drive shaft contactor in a turning position.
FIG.20 illustrates how the protruding member can prevent the pool cleaner from becoming stuck on a pool drain. The forward and rear retractable members are removed for visibility of the protruding member.
FIG.21 is a bottom view with the forward and rear retractable members removed so that the protruding member is more visible.
FIG.22 illustrates the pool cleaner climbing a vertical wall of a pool and extending above the waterline.
FIG.23 is a bottom view of the pool cleaner with the forward retractable member removed to show the position of the water ports and the waterline inFIG.22.
FIG.24 is a top view of the pool cleaner indicating the position of the waterline inFIG.22.
FIG.25 is a top view of the pool cleaner with the cover removed and indicating the position of the waterline inFIG.22.
FIG.26 is a side perspective view of the pool cleaner with one of the tracks removed.
FIG.27 is a side perspective view of the pool cleaner with the track drive mechanism removed to show how the guard can attach to the housing.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTSThis disclosure describes exemplary embodiments, but not all possible embodiments of the pool cleaner. Where a particular feature is disclosed in the context of a particular example, that feature can also be used, to the extent possible, in combination with and/or in the context of other examples. The pool cleaner and methods may be embodied in many different forms and should not be construed as limited to only the examples described here.
Referring initially toFIGS.1-8, certain features of an example of thepool cleaner100 are described. Thepool cleaner100 includes ahousing102 having aforward end104, arear end106, a top108, a bottom110, afirst side112, and asecond side114. Extending from the top108 is anoutlet port116 defined by anoutlet port housing118. Theoutlet port116 is in fluid communication with aninlet port120 defined on thebottom110 of thehousing102.
When suction is applied at theoutlet port116 via a suction hose (not shown), water and debris from submerged pool surfaces are drawn through theinlet port120 in order to clean the submerged surfaces. As will be explained later, such suction is also used to propel thepool cleaner100 in a forward direction F and a turning direction T.
Thefirst side112 andsecond side114 include arespect drive mechanism122 in mechanical communication with the suction. Thedrive mechanism122 drives thepool cleaner100 in various directions across the pool surface, including across the pool bottom and up the pool side walls.
In the example shown in the drawings, the drive mechanism is atrack drive mechanism122 and includes atrack124 wrapped around afirst wheel126 and asecond wheel128. Thefirst wheel126 is positioned rearward of thesecond wheel128. In the example shown, a diameter D1 of thefirst wheel126 is enlarged relative to a diameter D2 of thesecond wheel128. In other examples of thepool cleaner100, the drive mechanism may employ wheels without tracks.
Thebottom110 of thepool cleaner100 defines aplenum130 that creates an area of suction around theinlet port120. Theplenum130 includes a forwardvertical wall132 and a rearvertical wall134 extending downwardly from atop plenum wall136 and laterally betweenopposed plenum sidewalls138. Together, the forwardvertical wall132, rearvertical wall134,top plenum wall136, and opposedplenum sidewalls138 form a recessed area around theinlet port120 that enhances suction from theinlet port120 in theplenum130.
Theplenum130 also includes a forwardretractable member140 and a rearretractable member142. The forwardretractable member140 and rearretractable member142 are configured to contact the pool surface and extend and retract vertically as they move across obstacles such as large debris or drains on the pool surface.
The top108 includes acover144 that may be removed via acover latch146 to access mechanical components inside thehousing102. Thecover144 includes ahandle148 that allows a user to easily grab thepool cleaner100 to remove it from the pool when necessary.
A particularly advantageous feature of thecover144 is at least onevent mechanism150 formed adjacent theforward end104 of thepool cleaner100. Thevent mechanism150 is configured to allow water from outside thehousing102 and cover144 to flow into thehousing102 to help prevent loss of suction when theforward end104 extends above the water line of the pool. Thevent mechanism150 may be composed of one or more holes defined by thecover144 and extending completely through thecover144. This advantageous feature is described in more detail later.
In the example shown in the drawings, thevent mechanism150 includes a plurality of vent slits152 formed on opposed sides of theinlet port120. These vent slits152 extend from a point proximal to theforward end104 toward therearward end106 and do not extend past the position of theinlet port120.
Thevent mechanism150 need not have the exact construction shown in the drawings or described above. Thevent mechanism150, in certain examples, is positioned proximal to theforward end104, but does not necessarily have to be on thecover144.
Referring now toFIGS.9-11, additional details about the forwardretractable member140 and rearretractable member142 will now be described. InFIGS.9 and10, the forwardretractable member140 and rearretractable member142 are shown as transparent features so that their respective interiors are visible.FIG.11 is a cross section taken along the plane11-11 defined by the arrows inFIGS.9 and10.
In the example shown, both the forwardretractable member140 and rearretractable member142 are composed of a plurality of substantiallycylindrical rollers154 that roll independently of one another about asupport member156 extending fromopposed housing sidewalls158. Therollers154 have a diameter D3 selected so that anouter surface160 of the rollers may slightly contact or almost contact a either a forwardconcave wall162 or a rearconcave wall164 and the forwardvertical wall132 or the rearvertical wall134 of theplenum130. This construction allows eachroller154 to move independently of theother rollers154 over obstacles on the pool surface and to help concentrate suction in theplenum130.
Theretractable members140,142 have a considerable range of movement. As illustrated by the arrows inFIG.11, theouter surface160 of therollers154 can extend beyond anouter perimeter166 of thetracks124.
The construction of the forwardretractable member140 and rearretractable member142 is not limited to this example. For example, either or both of the forwardretractable member140 and rearretractable member142 may be replaced with flaps instead of rollers. Likewise, the forwardretractable member140 and rearretractable member142 may be composed of asingle roller154 or flap instead of a plurality ofrollers154 or flaps.
Referring toFIG.12, thecover144 has been removed so that the interior of thehousing102 is visible and details of theoutlet port housing118 can be described.FIG.13 is a side view of theoutlet port housing118 with nonvisible features shown in dashed lines.
Theoutlet port housing118 extends from theoutlet port116 at a top thereof to aturbine cover168 at a bottom thereof. Theturbine cover168 is configured to cover the turbine described below and direct water flow from the turbine up through theoutlet port116. Theoutlet port116 is defined by ahose nozzle170 that is rotatable about an axis A passing through the cylindrical center of thehose nozzle170. Making thehose nozzle170 rotatable allows thepool cleaner100 to turn without twisting the suction hose connected to thehose nozzle170.
The inside of theoutlet port housing118, which is illustrated by dashed lines inFIG.13 defines a water flow passage that directs water flow from theturbine172 up through theoutlet port116.
Referring toFIGS.14 and15, thepool cleaner100 with thecover144 removed and theoutlet port housing118 removed is shown so that details of thedrive train171 are visible. Thedrive train171 is powered by suction that causes theturbine172 to rotate. The motion of the spinningturbine172 is transferred to at least one of thefirst wheels126 via a plurality of gears in mechanical communication with adrive shaft174 that causes thefirst wheels126 to turn and power thedrive mechanism122 via apinion gear176.
InFIG.15, thetrack124 has been removed so that features of the inner side offirst wheel126 are visible. Thefirst wheel126 has aprimary wheel gear178 radially spaced from asecondary wheel gear180 opposing one another on an inside peripheral surface of thefirst wheel126.
Thedrive train171 allows thepool cleaner100 to move in the forward direction F and periodically make turns to so that thepool cleaner100 can move to different areas of the pool. The steering operations are controlled by moving thedrive shaft174 so that thepinion gear176 engages either theprimary wheel gear178 or thesecondary wheel gear180. When thepinion gear176 engages thesecondary wheel gear180, thefirst wheel126 moves in reverse, which causes thepool cleaner100 to turn.
Acam182 of thedrive train171 dictates whether thepool cleaner100 moves in the forward direction F or turning direction T. In the turning direction T, thepool cleaner100 changes direction relative to the forward direction F. Referring toFIGS.16-19, the perimeter of thecam182 includes alternating radiallyenlarged sections184 and radially constrictedsections186. Thecam182 is rotated by theturbine172 through use of reduction gears188.
Adrive shaft contactor190 mechanically connects thedrive shaft174 with thecam182 and is operable to move thepinion gear176 from a forward driving position to a turning position. InFIG.18, thepinion gear176 is in the forward driving position in which it engages theprimary wheel gear178. InFIG.19, thepinion gear176 is in the turning position in which it engages thesecondary wheel gear180.
Thedrive shaft contactor190 includes a rotatablecam contacting member192 that directly contacts thecam182 and is biased against thecam182 with at least onespring194 or the like that presses upward against anarm196. As shown inFIG.18, when thecam contacting member192 is in contact with a radiallyenlarged section184 of thecam182, thepinion176 is in the forward driving position. As shown inFIG.19, when thecam contacting member192 is in contact with a radially constrictedsection186 of thecam182, thepinion176 is biased by thespring194 into the turning position.
A particularly advantageous feature of thepool cleaner100 will now be described by referring toFIGS.20 and21 in which theretractable members140,142 have been removed from thepool cleaner100 for better visibility of certain features. A problem with pool cleaners is that they sometimes become stuck on drain covers D raised above the pool surface S. Thepool cleaner100 described here is configured to substantially prevent itself from becoming stuck on submerged obstacles such as drain covers D by including a protrudingmember198.
The protrudingmember198 extends downwardly from thetop plenum wall136 and longitudinally between the forwardvertical wall132 and rearvertical wall134. The protrudingmember198 is positioned between theinlet port120 and one of theplenum sidewalls138. A terminalbottom end200 of the protrudingmember198 is positioned higher than a terminalbottom end203 of theplenum sidewall138. Theforward surface202 of the protrudingmember198 tapers downwardly and rearwardly as it moves down fromtop plenum wall136 to the terminalbottom end200. Therear surface204 of the protrudingmember198 tapers upwardly and rearwardly as it moves up from the terminalbottom end200 to thetop plenum wall136. This tapered shape allows the protrudingmember198 to slide across surfaces easier than it otherwise would if the protrudingmember198 were rectangular with sharp vertices.
As shown inFIG.20, when the protrudingmember198 contacts the drain cover D, it causes thepool cleaner100 to tilt, which ensures at least one of thetracks124 can maintain contact with the pool surface to prevent thepool cleaner100 from getting stuck.
Another advantageous feature of thepool cleaner100 will now be described by referring toFIGS.22-25. As illustrated inFIG.22, when thepool cleaner100 climbs vertical pool walls W, it can sometimes rise partially above the pool's waterline. When this happens to a conventional suction pool cleaner, the inlet port sucks in air, causing the pool cleaner to lose suction and temporarily stop working until suction is regained. Thepool cleaner100 described here is designed to prevent loss of suction in this situation.
FIGS.22-25 indicate the position of the waterline on thepool cleaner100 inFIG.22 from different points of view. InFIGS.23-25, the forwardretractable member140 has been removed for better visibility of certain features. InFIG.25, thecover144 has also been removed for better visibility of certain features.
Suction loss is prevented by water passing through thevent mechanism150 through thehousing102 and out one ormore water ports206 formed on the bottom110. This water then falls over theplenum130 and substantially prevents loss of suction.
In the example shown, thewater ports206 are positioned directly beneath thevent mechanism150 and forward from the forwardvertical wall132 closer to theforward end104. Thewater ports206 are also positioned directly above the forwardretractable member140 as can also be seen inFIG.7. As used herein, the term “directly” means along the same vertical plane passing through the pool cleaner when it is in the orientation shown inFIGS.5-8.
In the example shown, there are twowater ports206 positioned on either side of theinlet port120. This permits water to flow across both sides of theplenum130. In other examples, there may be oneelongated water port206 extending across both sides of theplenum130 or there may more than twowater ports206 positioned about either side of theplenum130.
Referring toFIG.26, thetrack mechanism122 construction will be described in more detail. Thetrack124 is made of flexible plastic or rubber material suitable for use on a pool cleaner. Theouter perimeter166 of thetrack124 includestreads208 for enhanced traction with the pool surface. Aninner perimeter210 of the track includes a raisedridge212 extending substantially completely around theinner perimeter210. The raisedridge212 is sized to slide into afirst groove214 formed on a perimeter of thefirst wheel126 and asecond groove216 formed on a perimeter of thesecond wheel128. By making the raisedridge212 mate with the first214 and second216 grooves, thetrack124 is prevented from sliding off thefirst wheel126 andsecond wheel128.
Referring also toFIG.27, an advantageous safety feature of thepool cleaner100 will be described. One of the problems with conventional track-driven pool cleaners is that they have large spaces between the tracks and wheels where things such as fingers, hair, and clothing can become stuck. Thepool cleaner100 described here overcomes this problem by including aguard218 that fits between thefirst wheel126 andsecond wheel128. As shown inFIG.26, theguard218 substantially fills the space between thefirst wheel126 andsecond wheel128 to prevent object from entering the space.
InFIG.27, thetrack mechanism122 is removed so that the connection mechanism between theguard218 andhousing102 is visible. Theguard218 includes aninsertion member220 that is inserted into aguard receiving opening222 defined by the side of thehousing102. Aforward section224 of the guard and arear section226 of the guard substantially match the curvature of thesecond wheel128 andfirst wheel126 respectively so that there is only a small gap between these wheels and theguard218.
Most parts of thepool cleaner100 may be constructed of submersible plastic material and may be printed, machined, or molded to the desired shape. Where needed, parts may be connected together with substantially corrosion-proof fasteners such as stainless steel screws, washers, nuts, and the like. The first and second wheels may include conventional wheel bearings to aid rotation.
Thepool cleaner100 is not limited to the details described in connection with the example embodiments. There are numerous variations and modification of the compositions and methods that may be made without departing from the scope of what is claimed.